Industrial Attachment undertaken at Knit Concern Group Limited

Report on Industrial Attachment
Undertaken at
Knit Concern Group Limited
Course Code: TE – 411
Prepared by
Fazle Rabbi Rumman
Roll No.: 766 ; Reg. No.: 3223
Session: 2012 – 2013 (3rd
Batch)

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CONTENTS
Chapter Page No.
Acknowledgement………………………………....……………………………….... 2
Introduction…………………………………………………………………….…….. 4
Knit Dyeing Unit
1. Project description…………………………………………………………... 7
2. Manpower Management …............................................................................11
3. Different Sections...……………………………………………………..…. 16
4. Description of Dyeing Machines & Mechanism of working………...…….. 30…
5. Finishing Section & Machineries…………………………………...……… 40..
6. Raw Materials………………………………….……………………...…….55
7. Production Process & Sequences…………..…………………………...….. 59
8. Quality Assurance...……………………………………………………...….75
9. Maintenance System……………………………………………………...…85
Yarn Dyeing Unit
1. Project Description……………………………………………………...….. 93
2. Different Sections
Winding Section….................................................................................97
Laboratory……………………………………………………………102
Dyeing Section………….………….………………………………...104
Auto dossing system…………………………………………….…...111
Finishing Section……………………..……………………………... 113
3. Production Process…..…………….…………………………….…………115
Utility Section
1. Water Treatment Plant………...……………………………….………......123
2. Boiler………………………………………………………….…………... 125
3. Generator………….……………………………………………….……… 126
4. Compressor………..……………………………………………………… 126
5. Effluent Treatment Plant……………………………..………………….…127
Stores & Inventory……………………...……………………………………….….130
Marketing Activities…………………………...………………………………….. 133….
Conclusion………………………….………………………….………………….. 136
Special Thanks

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Introduction
The term “textile” derived from the Latin textilis and the French texere, meaning “to
weave,” and it originally referred only to woven fabrics. It has, however, come to include
fabrics produced by other methods. Thus, threads, cords, ropes, braids, lace, embroidery, nets,
and fabrics made by weaving, knitting, bonding, felting, or tufting are textiles. Some
definitions of the term textile would also include those products obtained by the papermaking
principle that have many of the properties associated with conventional fabrics. In addition
to clothing and home furnishings, textiles are used for such industrial products as filters to air
conditioners, life rafts, conveyor belts, tents, automobile tires, swimming pools, safety
helmets and mine ventilators.
At KNIT CONCERN LTD., cutting-edge technologies merge seamlessly with human
ingenuity and deep seat recommitment to ensure excellence in every stage and area of their
activities. From fiber to fabric, KNIT CONCERN LTD is truly integrated undertaking. The
KNIT CONCERN LTD. has the capability to offer a complete product range for the export
textile markets. The goal of KNIT CONCERN LTD. is to become the preferred partner for
sourcing high quality fabrics and clothing from Bangladesh with highly advanced technology
and an emphasis on developing local human resources. KNIT CONCERN LTD has the
potential to make an important contribution to the nation's growing ready-made garments
export sector.

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VISION OF KNIT CONCERN LIMITED
In the backdrop of a mercurial, ever-changing fashion world, knit Concern Ltd
considers its prime mission to suit every new taste, whim and demand of customers from
around the world and all strains of human culture.
KCL acts on the basic premise that “fashion is an exploration into the images people
seek to convey – about themselves and the way they live.”
So, in dealing with its target consumers, KCL mainly aims to know their perception
about themselves and translates those into garments. Doing that, over the years, KCL
designers have acquired an almost telepathic understanding of the consumers’ needs.
KCL has started manufacture and export garments since late 1990. Its mission is to
produce the latest design; quality knit fabrics and apparels for international markets.
KCL is one of the few elite private sector business groups, which contributed wealth as well as
welfare to the struggling economy of Bangladesh. As time is essential to space so is taste to its
products. The secret is love – which, paired with meticulous efficacy and a keen sensitivity to
style, makes KCL an emerging brand destined to light up the horizon of fashion.
KCL has team of skilled and dedicated technocrats backed by adequate number of
modern USA and European machinery and equipment to match international standard of all
kinds of knitwear products.

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GENERAL INFORMATION ABOUT THE FACTORY:
Name of the factory: KNIT CONCERN LIMITED
Type: 100 % Export Oriented Composite Knitwear Industry
Year of Establishment :1998
Status (Legal Structure) : Private Limited Company
Annual Production capacity: 10000 ton of knit fabric (Open & tubular form)
Total Manpower: Around 8000
Address: 62, Water Works Road, Godnail.Narayanganj, Bangladesh.
Telephone Number : +88 – 02 - 7641086
Fax Number : + 88 – 02 – 7641087
URL : http://www.knitconcern.com
 LOCATION OF KCL
Knit Concern Limited is located at Godnail , in Narayanganj about 18 km from the EPZ.

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 Product mix:
- 100 % cotton
- CVC (Chief Value Cotton) (60/40)
- Grey mélange
* 5 % Viscose & 95% Cotton
* 15 % Viscose & 85 % Cotton
- Ecru mélange (2%)
- Camel mélange (1%, 2%)
- PC (52/48, 60/40, 65/35, 80/20)
-Sewing thread.
 Project Cost:1000 core Taka (Approximately).
 Project Area: Approx. 82000 sq. ft.
 Physical Infrastructure:
Within only a decade, by hyper-growth has been transformed into a futuristic
entrepreneurial saga. Its production has branched out into four full-fledged factories at three
locations – God nail in Narayanganj and Mirpur in suburban Dhaka.
KCL’s God nail premise houses the parent organization and ultra-modern Unit-1, with seven-
story building as the main one. A new 10- story building is its subsidiary KC Apparels Ltd.
Its other subsidiary, Crescent Star Ltd, is located at Mirpur.
 Knit Dyeing Section:
It has two section of knit dyeing floor – KCL (old floor) & KCA (new floor). Each
contains around 100 thousands square ft area.
Production capacity: approximately 50 ton/day
 Yarn dyeing section:
AREA: 100 thousand sq. fit. Floor: MULTI-STORED FLOOR (25,000 sq. ft./floor).
PRODUCTION: 15 Tons/day (Approximately). It has two lifts, two cranes of capacity=10
tons. There is a Bas Bar (have no wire) system to facilitate production.

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 Different Departments:
Production Oriented Department:
1. Yarn store
2. Planning & Control
3. Batching
4. Chemical store
5. Winding section
6. Dyeing Section
7. Finishing Section
8. Dyeing lab section
9. Wet lab
10. Quality Control
11. Maintenance
12. Utility
13. Water treatment plant
14. Effluent treatment plant
Supporting department:
- Prochurement
- Merchandising
- Marketing
- IT
- HRD
- Finance & accounting
- Medical
- Personnel Administration
- Security
 Remarks: Knit concern management system is consisting of very skilled &
experienced personnel.

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Organ gram of man power in Dyeing Section:

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Management system:
 Buyer sample is send to G.M.
 Matching is done by lab in charge.
 Sample is prepared by asst. dyeing master.
 Sample is send to the buyer for approval.
 Approved sample is returned and taken as standard. Sample for bulk production.
 Asst. dyeing master gives responsibilities to production officer.
 Then production officer, with the supervisors start bulk production.
 On line and off line quality check is done by lab in charge and asst. dyeing master.
 After dyeing finishing in charge controls the finishing process with the supervision of
production officer.
 After finishing, the material is checked by asst. dyeing master.
 Finally G.M. checks the result with asst. dyeing master and decision is taken for
delivery.
Shift Change:
Two shifts (day and night): each of 12 hrs
Day shift 8 a.m. to 8 p.m.
Night shift 8 p.m. to 8 a.m.
RESPONSIBILITIES OF PRODUCTION OFFICER:
1. To give dyeing program slip.
2. To match production sample with target shade.
3. To collect production sample for sample matching nest production.
4. To observe dyed fabric during finishing running & also after finishing.
5. To identify disputed fabrics & report to production manager for necessary action.
6. To discuss with production manager about overall production if necessary.
7. To sign the store requisition.
8. Also to execute overall floor works.
9. To maintain loading / unloading Shee

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Manpower List (Dyeing Department)
No. Section Person
01 GM 01
02 DM 01
03 DDM 01
04 SPO 01
05 P.O 08
06 Planning 02
07 Q.C / Q.I 86
08 Maintenance 71
09 Batch 75
10 Dyeing 149
11 Finishing 139
12 Store 26
13 Delivery 29
14 Washing 26
15 Accounts 03
16 Marketing 02
17 Store (Acc) 02
18 Ex.Of./'Time 04
19 Pion 04
Total 650

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DESCRIPTION OF WORK OF A PRODUCTION OFFICER:
Report to: Sr. production officer
Job Summary: To plan, execute & follow up the production activities & control the quality.
DUTIES & RESPONSIBILITIES:
1. Overall supervision of dyeing, finishing production.
2. Batch preparation & pH check.
3. Dyes & chemical requisition issue & check.
4. Write fabrics loading & unloading time from m/c.
5. Program making, sample checking, color measurement.
6. Control the supervisors, operators’ asst. operator & helpers of dyeing m/c.
7. And also any other work as & when required by the management.
Remarks:
In this dyeing plant all the P.O, S.P.O & D.M are technical person. Thus why efficiency of
this section is very high.

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Different Sections: (according to flow of operation)
Knitted fabric from Knitting
Grey Fabric Inspection Section
Batch Section
Dyeing Laboratory
Dyeing Floor
Finishing Section
Quality Checking
Dispatch/ Delivery Section
Supporting sections:
1. Planning
2. Chemical store
3. Utilities Sections – water, power, boiler, compressor, waste water
management system.
4. Maintenance Section

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Grey Fabric Inspection Section
Overview of knitting section:
1. Total no. of knitting m/c –
2. Types of m/c – Single jersey, double jersey, Fleece m/c, Auto-stripper m/c etc.
3. Types of Fabric Produced –
• Single jersey
• Single jersey with lycra
• Interlock
• Fleece
• Single Lacoste
• Double Lacoste
• Pique
• Rib with & without Lycra
• 1x1, 2x2, 2x1, 9x1, 9x2, 7x5 Rib
4. Cotton Yarn count frequently used – 20, 24, 26, 28, 30, 34, 40, 42, 48 etc. & for
special organic fabric 50 count yarn is used.
5. Production Capacity – 30 tons/day.
Inspection of Grey Fabric from knitting section to Dyeing:
1. Objective: - to find-out any kinds of faults in the grey fabric before dyeing
operation, by thorough checking up.
- To ensure maximum quality assurance by double
checking.
2. Checking flow-chart –
Knitted fabric (checked in knitting section)
Grey fabric inspection section for checking by dyeing dept.
Checking
Ok Not ok
To storage/ batch section Recheck
Dyeing If not ok, Rejection
3. Checking Standard: Varies depending on buyers’
requirements. For H&M – 4-point system is followed. For
others – 10-point system is followed.
4. Frequently found faults:
a. Loop
b. Hole.
c. Set-up.
d. Needle broken
e. Yarn-out

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f. Patty
g. PATTA
h. Contamination
i. Lycra-out
j. Sinker-mark
k. Star-mark
l. Wheel-mark
m. Oil-mark
n. Groove-mark
o. Needle-mark
p. Thick-Thin stripe
q. Wavy Stripe.
Inspection Machine Specification:
- UZU machine for garment
- Width: 69 & 100 inch
- No of m/c: large – 3 small – 6
- Power supply required: 200 volt 50/60 Hz
- Motor- 1 hp.
- Efficiency – 75%
- Brand Name: UZU
Model: HC-TIM
1500mm
Country of Origin:
Thailand No of motor: 02
Motor: 210
HP Power:
220 V
Inspected Fabric Storage Section:
- Two storied storage sections with racks of multistoried rails.
- Total capacity – approx. 250 tons
- Storage fabrics are sorted and separated under following
parameters----
1. Buyer
2. Order no
3. Color
4. Count
5. Brand
6. Yarn lot
7. Fabric Diameter & GSM.

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Batch Section
Batching: Batching means separation of fabric according to specification, Dyeing
machine capacity & availability, urgency of the order.
Two types of Batching: 1. Solid 2. Assorted
Batch contains body of garments as well as collar-cuffs according to the design.
Total required quantity X Dia Quantity
Batch Quantity =
Total quantity
Total batch quantity + total parts
Batch Ratio =
Batch Quantity
Batch distribution: Batch is distributed according to nozzle capacity.
- During distribution maximum equilibrium of different
parts is taken into consideration.
- Lycra fabrics are slit-cut to heat-set. That’s why before
dyeing they need to re-sewn. This is done by ‘Bag-sewing’
machine.
- Tubular fabrics are turned into their backside by turning
machine.
List of machines in Batch Section:
Batch Section
Bag sewing m/c Manufacture:
MTG MECCANICA SNC
Country of Origin: Italy
Turning m/c
Brand Name: HSING
CHENG Model: HC-TFM-
1500 mm Country of
Origin: Thailand No of
motor: 02
Motor: 210 HP
Power: 220 V
Year of Manufacture: 2005
03
02
Plaiting m/c 02

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Planning Section
Objectives: To follow-up total lead-time of any order & maintain schedule. After getting every
order all planning required from yarn to dyeing is done by planning section.
Activities:
- Order for yarn.
- Give time limit to knitting.
- Machine & nozzle distribution after getting the fabrics fro knitting.
- Light shades are generally planned to do first.
- In case of critical color small batch is planned first.
- No. of batch is kept as minimum as possible.

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Central Laboratory
Knit concern has a ‘Central Lab’ including three major sections – Knit-Dyeing lab,
Yarn-Dyeing lab & Physical Lab.
Main Responsibility
1. Accepting the ‘Swatch’ from the buyer and analyze the color & Dyes.
2. Preparing the Recipe accurately matching the required color.
3. Storing & maintain the dyes to be used for dyeing.
4. Producing self-shades & storing it into the computer.
5. Record & analysis of chemicals & dyes quality.
6. Making plans for bulk dyeing.
7. Following the color coding system given by the distinctive buyer & also prepare
own color bank.
8. Testing the dyed goods.
Flow of work:
Swatch from buyer/merchandiser
(Contains: fabric construction-gsm-color name-color code-style)
Shade matching by lab works
Shade submission
(Sample match A, B,
C)
Approved Rejected
Recipe delivered for bulk-production

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Shade matching system:
Spectrophotometer
Spectrophotometers designed specifically for the measurement of colored materials, are at
Centre of any modern color formulation, color production, or color quality control system.
Although these color spectrophotometers are designed measure samples both accurately &
repeatedly, they accomplish these measurements only within a range of applicable tolerances.
Spectrophotometers are not perfect measuring devices, & how well they measure often depend
on factors under control of system operator. The objective is how to better operate and control
color spectrophotometers, so that their measurements are as accurate & repeatable as possible.
These tips are intended for those attempting to get the best possible measurement performance
from their color measuring spectrophotometer
The Data color high performance bench top spectrophotometers (Data color 650™, Data color
600™, Data color 400™) are the newest generation of bench top color measuring instruments,
incorporating state-of-the-art CMOS integrated circuit technology in the instrument design. All
are intended for use as a device for measuring, specifying and evaluating color in both
laboratory and production settings.
[Spectrophotometer – Data color model 600]
This high-precision, close-tolerance, reference grade spectrophotometer has special
capabilities to handle fluorescent materials.
❖ Automated zoom lens and specular port
❖ Exceptional inter-instrument agreement
❖ Automated UV control
❖ Multiple viewing apertures with automatic aperture recognition
❖ Automatic gloss compensation

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Pantone book:
- Buyer’s Swatch: may be piece of fabric or C.I. number of any specified
‘Pantone book’.
- There are 4 types of pantone book is available:
1. TP ----- textile paper
2. TC ----- textile cotton
3. TPX --- textile paper for bright
4. TCX --- textile cotton for bright
- The given swatch is measured by the ‘Spectrophotometer’, which is
prepared by reach memory of different dyestuff self-shades.
- Also the matching may be done by previous working record.
Some self-shade samples:
1. Dyechufix Yellow HS-3R :
0.01% 0.05% 0.1% 0.5% 1% 2% 3% 4% 5%

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2. Amron Red HR2D
0.01% 0.05% 0.1% 0.5% 1% 2% 3% 4% 5%
3. EV Blue SP. EBR
0.1% 0.5% 1% 2% 3%
4. Reactive Yellow 4GL
0.1% 0.5% 1.0% 2% 3%

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List of machine:
Auto lab Dispenser & Solution maker 01
Ahiba Naunce-( Sample
01
Dyeing m/c)
Sandolab sample d/m 04
Lab Extractor 01
Dryer 01
Data color
Spectrophotometer SF 01
600 Plus CT
Incubator ( Oven ) 01
Lay out of Knit-Dyeing Lab:

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Lab Dyeing Machine:
AHIBA NUANCE Data color lab dyeing machine
Feature
1. Easy to operate multi-step controller with alpha-numeric program names
2. Advanced microprocessor technology controls the heating and cooling system
3. Dyeing parameters are constantly monitored during every step of the dyeing process
and displayed on the large graphical display
4. Memory cards store an unlimited number of processes
5. Increased power output ensures reproducible level dyeing
6. Suitable for all substrate.

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Description of Dyeing Machines
& Mechanism of working

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Dyeing Floor
Knit concern Dyeing floor consists of two separate floors – KCL & KCA.
The Dyeing Machines are all Winch dyeing m/c of both atmospheric & high temperature
types.
Type capacity no. of m/c
Sample dyeing machine – 10 kg 3
20 kg 4
30 kg 7
60 kg 3
100 kg 2
Bulk dyeing machine - 150 kg 5
200 kg 2
250 kg 3
300 kg 2
400 kg 4
500 kg 2
600 kg 2
750 kg 3
800 kg 3
1000 kg 2
1200 kg 1
1500 kg 2
2200 kg 1
In KCL there are mainly two types of dyeing machine - - -
 Atmospheric machine: these runs in atmospheric pressure.
 High temperature & High Pressure (HTHP)

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Lay out plan of Dyeing sections:

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Details of Dyeing Machines in KCL
Specification of dyeing machines:
Fong’s Sample dyeing m/c
m/c
Sample Machine
Machine No: 09
Brand Name: FONGS
Model: ALLFIT -6O
Serial No: 28015417
Country Of Origin: Honkong
Machine Type :HP/HT
Machine Capacity: 6O Kg
Cycle time: 03 min
No of cycle : 12
Main pump speed: 80-150 m/min
Winch speed: 250 m/min
No of Nozzle: 02
No of motor: 08
Power: 415 V 3 @ 50 Hz
Water supply pressure req. : 300 Kpa
Compressed Air pressure required : 700 Kpa
Steam pressure required : 700 Kpa
Design temp. : 140 ° C
Year Built : 2003
Machine No: 10
Brand Name:
FONGS Model:
ALLFIT -6O Serial
No : 26012103
Country Of Origin : Honkong
Machine Type :HP/HT
Machine Capacity: 100 Kg
Cycle time: 03 min
No of cycle : 12
No of Nozzle: 02
N o of motor: 08
Power: 415 V 3 @ 50 Hz
Compressed Air pressure required: 700
Kpa Steam pressure required : 700 Kpa
Design temp. : 140 °
C Year Built : 2001
Machine No: 11 A
Brand Name: FONGS
Model: ALLFIT -30
Fong’s HTHP (Jumbo flow) winch
dyeing
(Capacity 2200 kg)
Bulk Machine
Machine No: 01
Brand Name: FONGS
Model: GN 6-SR -6T
Serial No :26012102
Machine Type: HP/HT Machine
Capacity: 1200 Kg
Cycle time: 03 min
No of cycle : 12
No of Nozzle: O6
No of motor: 08
Power: 415 V 3 @ 50 Hz
Compressed Air pressure required: 700 Kpa
Year Built : 2002
Machine No: 2A
Brand Name: FONGS
Model: GN 6-SR -4T
Serial No :26012101
Machine Type: HP/HT Machine
Capacity: 800 Kg
Cycle time: 03 min
No of cycle : 12
No of Nozzle: 04
No of motor: 08
Power: 415 V 3 @ 50 Hz
Year Built : 2002
Machine No: 2B
Brand Name: FONGS
Model : GN-18 M-4 T

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Serial No :26011959
Country Of Origin:
CHINA Machine Type
:HP/HT Machine
Capacity :30 Kg Cycle
time: 03 min
No of cycle : 12
Main pump speed :80-150 m/min
No of Nozzle : 01
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 2001
Machine No: 11 B
Brand Name:
FONGS Model:
ALLFIT -30 Serial
No :29017180
Machine Type :HP/HT
Machine Capacity :30 Kg
Cycle time: 03 min
No of cycle : 12
No of Nozzle: 01
No of motor: 08
Power: 415 V 3 C 50 Hz
Kpa Steam pressure required: 700 Kpa
C Year Built : 2004
Machine No: 11 C
Brand Name:
FONGS Model:
ALLFIT -30 Serial
No :29017183
Machine Type :HP/HT
Machine Capacity :30 Kg Cycle time: 03
min No of cycle : 12
No of Nozzle: 01
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 2004
Machine No: 11 D
Brand Name:
FONGS Model:
ALLFIT -30 Serial
No :29017182
Machine Type :HP/HT
Cycle time: 03 min
No of cycle : 12
No of Nozzle: 0 1
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built: 2004
Machine No: 11 E
Brand Name: FONGS
Model: ALLFIT -30
Serial No :29017181
Serial No :2G011473
Machine Type :Environmental
Cycle time : 03 min
No of cycle 12
Winch speed :250 m/min
No of Nozzle: 04
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 2001
Machine No: 2C
Brand Name: FONGS
Model: GN-18 M-4 T
Serial No :24010297 Country
Of Origin : Honkong
Machine Type
:Environmental Machine
Capacity :800 Kg Cycle time:
03 min
No of cycle : 12
No of Nozzle: 04 No of motor:
08 Power: 415 V 3 @ 50 Hz
C Year Built : 2000
Machine No: 3A
Brand Name: FONGS
Model: GN-6 SR-3T
Of Origin : Honkong
Machine Type: HP/HT
Cycle time: 03 min
No of cycle : 12
No of Nozzle: 03
No of motor: 08
Power: 415 V 3 @ 50 Hz
Compressed Air pressure required : 700
C Year Built : 2002
Machine No: 3B
Brand Name: FONGS
Model: GN-18 M-3T
Serial No :24010325
Country Of Origin : Hong kong
Cycle time: 03 min
No of cycle : 12
No of Nozzle : 01
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 2000
Machine No: 4A
Brand Name: FONGS
Model: GN-6-2T
Serial No :23009446

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Machine Type :HP/HT
Machine Capacity :30
Kg Cycle time: 03 min
No of cycle : 12
No of Nozzle : 01
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 2004
Machine No: 12
Brand Name:
FONGS Model:
GN-18 Serial No
:24010324
Country Of Origin: CHINA
Cycle time: 03 min
No of cycle : 12
No of Nozzle: 0 1
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 2000
Machine No: 13
Sample Dyeing m/c:
Brand: Ugoloni
Origin : Italy
Capacity: 20 Kg.
Machine Type :HP/HT
Machine Capacity :400
Kg Cycle time: 03 min
No of cycle : 12
No of Nozzle: 02
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 1998
Machine No: 4B
Brand Name: FONGS
Model: GN-18 M-2T
Of Origin : Honkong
Machine Type
:Environmental Machine
03 min
No of cycle : 12
No of Nozzle : 01
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 1998
Machine No: 4C
Brand Name:
FONGS Model:
GN-18-2T Serial No
:23009200
Machine Type: Environmental
Machine Capacity: 400Kg
Cycle time: 03 min
No of cycle : 12
No of Nozzle: 02
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 1998
Machine No: 4D
Brand Name:
FONGS Model:
ECO-6-2T Serial No
:28015334
Country Of Origin :
Honkong Machine Type:
HP/HT Machine Capacity:
400 Kg Cycle time: 03 min
No of cycle : 12
No of Nozzle: 02
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built: 2003
Machine No: 5A
Brand Name: FONGS
Model: GN-6-1T

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Serial No :23009447
Machine Type :HP/HT
Cycle time: 03 min
No of cycle: 12
No of Nozzle: 01
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built: 1998
Machine No: 5B
Brand Name: FONGS
Model: GN-18 M-4 T
Of Origin : Honkong Machine
Type :HP/HT Machine
03 min
No of cycle : 12
No of Nozzle: 0 1
No of motor: 08
Power: 415 V 3 @ 50 Hz
Design temp.: 140 °
C Year Built: 1998
Machine No: 6A
Brand Name:
FONGS Model:
ECO-38-6T Serial
No :28014582
Cycle time: 03 min
No of cycle: 12
No of Nozzle: 02
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built: 2003
Machine No: 6B
Brand Name:
FONGS Model:
ECO-38-6T Serial
No :28014581
Cycle time: 03 min
No of cycle : 12
No of Nozzle: 06
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 2003
Machine No: 7A

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Brand Name: FONGS
Model: ECO-38-4T
Of Origin : Honkong
Cycle time: 03 min
No of cycle: 12
No of Nozzle: 02
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 2003
Machine No: 7B
Brand Name:
FONGS Model:
ECO-38-4T Serial
No :28015423
Cycle time: 03 min
No of cycle : 12
No of Nozzle: 02
No of motor: 08
Power: 415 V 3 @ 50 Hz
C Year Built : 2003
Machine No: 08
Brand Name:
FONGS Model:
ECO-38-3T Serial
No :28015422
Cycle time: 03 min
No of cycle: 12
No of Nozzle : 02
No of motor: 08
Power: 415 V 3 @ 50 H

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Mechanism of Dyeing Machines
Main Parts of Dyeing Machine: 1. Main Vessel or Chamber
2. Winch roller or Reel
3. Heat Exchanger
4. Nozzle
5. Reserve Tank
6. Chemical dossing tank
7. Utility lines i.e. water line, drain line, steam inlet
etc.
8. Controlling unit or Processor
9. Fabric Plaiter
10. Different types of motors & Valves
Working Principle of Winch dyeing machine:
Winch Dyeing machines are most suitable for knit fabric dyeing. Here fabric is dyed in
tubular from where fabric runs in endless circular path. Inside the m/c the upper part of the
fabric runs through a nozzle & the lower part is immersed into liquor, in the nozzle the liquor
is sprayed onto the fabric. The fabric and liquor both circulated by a high pressure pump.
Fig: cross-sectional diagram showing fabric path & nozzle in the high pressure winch d/m
The main pump draws the liquor from the bottom of the vessel & passed this liquor through
the heat exchanger to the top of vessel into the Nozzle. The winch roller or the reel also helps
running the fabric smoothly. The liquor gets heated or cooled by exchanging temperature in
the heat-exchanger.

36
Fig: schematic diagram of the circulation system of liquor in a dyeing machine
General Parameters of Dyeing machines:
Capacity per nozzle: theoretically 250 kg but practically not more than 200 kg
should be used.
Nozzle pressure: 4-6 psi
Steam pressure: 7 bar (inlet of heat exchanger)
Cold water temp.
& pressure: 25 c & 3 bar
Maximum temp.: 140 for high temp. M/c 100 for atmospheric
Reel/Winch speed: 150-250 rpm
Main motor efficiency: 80-85%

37
Finishing Section
Textile finishing, in a restricted sense, is the term used for a series of processes to which all
bleached, dyed, printed & certain greige fabrics are subjected before they are put to market.
It’s one of the most important operation in knit processing.
Objectives of Finishing
-Improving the appearance, luster, whiteness etc.
-Improving the feel, which depends on the handle of the material & its softness, suppleness,
fullness etc.
-Wearing qualities, non- soiling, anticrease, antishrink comfort etc.
-Special properties required for particular uses -water -proofing flame proofing etc.
Covering of the faults in the original cloth.
-Increasing the weight of the cloth.
Effects of Finishing
1. Easy Care
2. Crease Recovery
3. Dimensional stability
4. Good abrasion resistance
5. Improved tear strength
6. Good sew ability
7. Soft or stiff handle
8. Shine or luster
Knit fabrics require finishing process after dyeing. During dyeing all knit fabrics are
dyed in tubular form. According to buyers requirement dyed fabrics are finished in either
Tubular form or Open-width form.
Depending on which Finishing sections are separated into two sections – OPEN &
TUBE section.

38
 Open-finish Section:
Those fabrics which are to be cut in open form in garment section as per buyer requirement
are finished in open form in this section.
The flow of process is as follows-
Hydro extractor
Slitting & dewatering
Stenter
Compactor
Q.C
Delivery
Layout of Open-Finish Section

39
Tubular Fabric Finish Section:
Tubular fabrics are generally used for Ladies wear & Baby dress. In KCL huge orders
of tubular product are manufactured.
The Machines or Finishing Sequence for Tube-Finishing are as following –
Hydro extractor
Dryer
Turning m/c
Plaiting m/c or Steam setting m/c
Tube Compactor
Layout of Tube-Finish Section

40
Description of Different Finishing
Machines
HYDRO-EXTRACTOR-PADDER
Manufacturer : SANTEX, SWITZERLAND
No. of m/c : 2
Manufacturer : BIANCO, ITALY
No. of m/c : 1
Function:
1. To remove the excess water inherited by the fabric during Dyeing.
2. To clean any unnecessary dirt or hairs of fibers.
3. To soften the fabric if required by using softening agent.
4. Slight controlling of Dia of tube fabric by using ‘Shaper’.
Important Parts & Zones:
Detwister : Un-rove the roped form fabric after dyeing by twisting & turning.
J-Box : Overfeeding zone, which ensures tension-free movement of fabric.
Water &
Softener bath: 1st
bath is only water, 2nd
one is for softener.
Padder : Two pairs of padding rollers set at the top of each bath. They
squeeze the excess water from the fabric.
Ring & Ring Pulley: Works as a guide of fabric & maintain required Dia.
Technical Parameter
1. Fabric Passing Speed: Depends on count & gsm.
For low GSM fabric – 60-65 m/min
For Medium - 55- 58 m/min
For High - 50-52 m/min

41
2. Overfeed regions: J – box, Before Padder 1 & Padder 2
3. Pressure in Padder: Padder 1 – 4-5 bar
Padder 2 – 3.5- 4 bar
4. Types of Softener used: Anionic, Cationic & Silicon softeners are used.
pH of bath should be 4.5-5.0
Concentration of softener – 10 g/l
Bath is changed after every 100 kg fabric.
5. Dia of Shaper: Max. 52 inches
Min. 18 inches
6. Water recovery%: 140-150%
7. Power consumed: 400 v. 50 Hz.
 DRYER
Manufacturer : SANTEX,
SWITZERLA
ND.
Function:
FONG’S, HONGKONG.
1. To dry the wet fabric.
2. Control the shade & gsm slightly.
Main Parts:
1. Feed unit; contains conveyor belt & number of rollers.
2. Two drying sections – i) upper level (3 chambers)
ii)Lower level (3chambers)
3. Heating system associated by STEAM Line & Nozzles.
4. Blower, to spread the steam through-out the chambers.
5. Exhaust air ventilator.
Technical Parameters:
Temperature : For colored fabric –
Chamber 1 –
140 c
Chamber 2 –
150 c
Chamber 3 –
130 c
For White (bleached) - all chambers -
120 c
Working width : 3000 mm
Speed : 8-80 m/min
Nozzle distance : 35-55 mm
Power consumption : 140 kw

42
 TUBE COMPACTOR
Manufacturer :
SANTEX,
SWITZERLAND
No. of m/c – 1
TUBETEX, USA
Function:
No. of m/c – 2
To control Dimensional stability of fabric.
Control GSM of fabric.
Make Shiny effect on fabric surface.
Main Parts of Compactor:
Feed section – tension control & metal detector.
Shape – Set according to the dia of fabric
Steam zone.
Take out & Plaiter zone
Compacting Zone: It’s a roller & shoe arrangement & the most important zone which
consists of two rollers, the Feed roller (recarter roller) & the Retard roller. They are
heated by Shoe, into which hot thermo-oil runs through.
Technical Parameters
Speed of passing fabric : 22-40 m/min
Shaper length : according to required Dia
Overfeed ratio : Edge drive zone – 1.0-1.5
Retard roller – 0.80-0.85
Take-out zone – 0.85-0.90
Conveyor belt – 1.0-1.05
Plaiter – 0.80-0.85

43
Compaction% : according to Shrinkage result
S/J – 10-15%
Rib – 10-12%
Interlock – 8-10%
Pique – 7-8%
Shoe pressure : S/J – large dia – avg. 30 psi
S/J – smaller dia – 10-15 psi
Rib – 10-20 psi
Lycra - <10 psi
Power consumed : 80 kw
Thermo-Oil temperature : 90 c

44
 SLITTING MACHINE
No. of machines : 3
Manufacturer :
BIANCO,
ITALY.
Function:
Slit-cut the tubular fabric through the needle mark.
Remove excess water.
Prepare the fabric for next operation.
Slitting Machine Material Passage (Left to
Right)
Main Parts:
Squeezer
J-box
Detwister
Spreader
Rotary cutting blade
Auto Centering system
Conveyor & Plaiter
Technical Parameters:
Speed : Varies with type of fabric
Overfeed : In feed zone, cutting zone, Conveyor belt (20-30%)
Pressure : In Detwister zone-0.5 bar, in Padding – 4-5 bar

45
 STENTER
No. of machine : 3
Manufacturer :
BRUKNER,
GERMANY (2)
TUBETEX, USA (1)
Function:
1. To dry the fabric.
2. Heat-set the synthetic fiber fabric.
3. Controlling the width of fabric or maintain dimensional stability.
4. Controlling the GSM of fabric.
5. Skew ness & Bowing controlling of stripe fabric.
6. Spirality & Twisting control.
7. Fabric hand-feel modification-like-Softening or Hardening.
8. Shade control.
9. Gumming & Cutting.
Stenter m/c (full length view) Stenter m/c (chain & clip system)
Important Zones & Parts:
1. Back Zone
- Guider
- Two Baths & Padder or Squeezer
- Auto centering
2. Middle Zone
- Over feed regions
- Bianco or Mahlo arrangement.
- Chain & clip system
- Chambers (Contains blower, heater, recovery)
3. Front Zone
- Over feed zone
- Plaiting
- Static electricity remover.

46
Fabric path of stenter
Overfeed & pinning
Fabric in the chain
Extra attachment:
i) Mahlo attachment for bowing control.
ii) Selvedge gumming device
iii) Selvedge cutting device
Fuel used for heating : Gas (for Gas-Stenter)
Thermo-Oil (for Oil-Stenter)
Working Width : 600-2600 mm
Total Length : 138 ft
No. of Chambers : 8
Chamber length 10 ft each
No of Motors : 96
Padder Pressure : Max. air Pressure – 10 bar (avg. 5-7)
Max. Steam Pressure – 0.7 bar
Overfeed Ratio : Back Zone – 0-5
Master overfeed – 80% (in case of heat-set
15-20%)
Wheel overfeed – 3%
Feed overfeed – 3-5%
Take-up overfeed – 15-20%
Temperature : Normal – 130-150 c
Heat-Set – 180-210 c

47
Speed of Passing Fabric : Normally 35-40 m/min
Heat set 18-22 m/min
Width Controlling : S/j +1-2 inches
Interlock/Rib - 1%
Lycra +8-10%
Padder bath capacity : 250 lit
Types of Softener used :
White, Color, Silicon
Softener
Production:
Capacity: 5 tones/shift
Actual production: 3.5-4.5 tones/shift
Heating Arrangement
For Gas Stenter: Rotamatic Burner
For oil Stenter: Thermo-oil
Parameters used for different types of fabric:
BRUCKNER
Fabric Req. Finish R F B Temperature Speed Over
GSM GSM m/min feed
S/J 140 - 68” 71” 67” 140 14 80%
” 160 150/52 56” 64” 60” 150 20 80%
” 180 170/72 54” 56” 54.5” 110 12 60%
“ 190 188/90 58” 61” 57” 110 15 80%
H/J 280 270/75 64” 67” 62” 110 7 80%
Loop 280 255/60 74” 78” 75” 110 9 80%
back
Fleece 260 260/65 74” 80” 75” 110 9 80%
1×1 rib 240 224/26 72” 75” 74” 110 10 80%
Bolton 330 340/45 62” 67” 65” 130 10 80%
stripe

48
 OPENWIDTH COMPACTOR
M/C quantity : 01
Brand : Brukner, Germany
Maxm line speed : 60 m/min
Useable line speed : 30 m/min Maxm dia :95 "
Workable dia : 90"
Steam box temp. : 80° C
Feed R/L temp. : 105° C
Over feed ( %) : upto 50 %
Shoe pressure : Max-18 Min-5
Sensor Position : -Shoe pressure ( One shoe )
-Retard Roller ratio
-Pliater Ratio
-Right-Left roller pressure
Function of the Machine:
1. To compact the fabric
2. To control the shrinkage
3. To maintain proper width and G.S.M
Heating system: Steam
Main parts of the machine:
1. Heating chamber
2. Blower (2, one at the entry chain zone for uncurling and another at the entry of
compacting zone)
3. Synthetic blanket as a conveyor,
4. Folder
5. Exhaust fan
6. Unpinning cylinder (-40% +40%)
7. Belt cylinder (-40% +40%)
8. Uncurling device at entry of compacting zone.
9. sensor
10. brush roller
Additional attachment:
i) Selvedge cutting
ii) Selvedge safety
iii) Pinning safety
iv) Selvedge unrolling

49
Compacting zone
Fig. Material Passage
Production: Capacity: 5 tones/shift or 10 tons/day
Actual production: 4 tones/shift.
Utility: Steam Electricity, Compressed air.

50
Special Finishing Machines
 Sueading or Carbon Finishing or Pitch Finishing:
No. of m/c: 2
Manufacturer: LAFER, ITALY
Function
Make the surface of fabric Smooth
Improve heat insulation properties.
Good Hand feel.
Types wires – Carbon
Fabric speed – S/J : 8-11 rpm
Rib/Interlock: 9-10 rpm
Terry fleece: 10-11 rpm
Tension – 10-16 kg-wt
Drum rpm – 20-25 rpm
Specification:
No of motor: 08
Winch speed: 10-30m/min
Machine speed: 50m/min (max)
Drum speed: 30-35-50 rpm (Max
70)
Pile roller no: 06 Pile
made of Plastic Plaiter
tension: 6kg Taker in
tension: 20kg
Fabric return driver Tension: 25kg
Material Passage
Drum Tension: 50kg Speed
range: 10-40 m/min No of
cylinder/drum:
2 for double cylinder
1 for single
cylinder No of pin roller: 24
2 = 48 24 1= 24
Cylinder r.p.m (General):
100 Tension: 3 kg

51
 Raising or Brushing
M/C quantity : 01
Brand -GEMATEX
Model: KRM 6725
Origin-Germany
Year of manufacture-1999
Voltage - 400 V
Nominal Current -63 A
No of Pile :12
No of Counter-Pile :12
Function
To raise or tear-out the extra thread loops on the back-side of fabric
Increase the warmth of fabric.
 Singeing
No. of m/c- 1
Manufacturer- OSTHOFF – SENGE, GERMANY
Function
To remove the hairs form fabric surface by burning in extremely heated flame.
Technical parameters
Flame temperature : 100-110 c
Fabric speed : max 90 m/min
Remarks:
Knit Concern ltd. is a well-equipped industry. It contains machinery of well-known
brands like Bruckner, Bianco, Santex, etc. The availability of these machines is helpful to
increase the productivity of the industry. The arrangement of machines is very beautiful and
there is enough space for movement of the workers.

52
Raw Materials Used in
Different Sections

53
Raw Material for Knitting
The raw material for knitting is the yarn. Different types of yarn of wide range of count are
used. In yarn store section we had the chance to know about different yarns of different count
used in knitting. We also have known different yarn manufacturer/suppliers name for this
knitting section i.e. sources of yarn. Both carded and combed yarn is used for knitting.
Generally used yarn and their count:
Cotton 24
S
, 26
S
, 28
S
, 30
S
, 32
S
, 34
S
, 40
S
Polyester 75D, 100D
Spandex yarn 20D,40D, 70D
Grey Mélange (C_ 24
S
, 26
S
Ecru Mélange (C-85% V-15%) 24
S
, 26
S
, 28
S
PC (65%Polyester & 35% cotton) 24
S
, 26
S
, 28
S
, 30
S
CVC 24
S
, 26
S
, 28
S
, 30
S

54
RAW MATERIALS FOR
DYEING
In the industry the raw materials used for production are:
1. Grey fabrics
2. Dyes
3. Chemicals.
1. Grey Fabrics:
Following types of gray fabrics are dyed:
1. Single jersey
2. Single jersey with Lycra
3. Polo pique
4. Single lacoste
5. Fleece
6. Interlock
7. Interlock with Lycra
8. Rib
9. Rib with Lycra
10.1Χ1
rib
11.2Χ2
rib
12. Different types of collar & cuff

55
2. Dyes
The following dyes are
used: 1.Reactive
2.Disperse
Name of Dyes Origin
Supplier
Cibacron Yellow - F4G Singapore Swiss color
Cibacron Yellow FN2R Singapore Swiss color
Cibacron Orange - FNR Singapore Swiss color
Cibacron Scarlet -F3G Singapore Swiss color
Cibacron Red-FN3G Singapore Swiss color
Cibacron Red-FNR Singapore Swiss color
Cibacron Red-FN2BL Singapor Swiss color
Cibacron Scarlet -FN6G Singapore Swiss color
Cibacron Navy -WB Singapore Swiss color
Cibacron Red -WB 150 % Singapore Swiss color
Cibacron Red -HDN 200 % Singapore Swiss color
Cibacron Turquish -HGN Singapore Swiss color
Bezactive Red SLF Swisterland RH corporation
Bezactive Yellow S-MAX Swisterland RH corporation
Bezactive Blue S-GLD Swisterland RH corporation
Bezactive Blue SLF Swisterland RH corporation
Bezactive Red S-3B Swisterland RH corporation
Bezactive Red S-MAX Swisterland RH corporation
Bezactive Yellow S-8G Swisterland RH corporation
Terasil Black SRL-O1 Singapore Swiss color
Terasil Black W-NS Singapore Swiss color
Terasil Blue BGE-01 Singapore Swiss color
Terasil Blue WBLS Singapore Swiss color
Terasil Navy GRLC Singapore Swiss color
Terasil Red WRS Singapore Swiss color
Terasil Violet BL-01 Singapore Swiss color
Terasil Yellow W-4G Singapore Swiss color
Remazol Blue-RR German Dyester
Remazol Yellow-RR German Dyester
Remazol Red -RR German Dyester
Remazol Brillient Yellow -
German Dyester
3GL
Remazol Tarquise Blue-G German Dyester
Livafix Rubina CA German Dyester
Livafix Red CA German Dyester
Livafix Blue CA German Dyester
Livafix Yellow CA German Dyester
Livafix Amber CA German Dyester
Livafix Orange CA German Dyester
Livafix Bri Yellow CA German Dyester
Reactive Black GRC China LC

56
Reactive Black B China LC
Reactive Red 3RS China LC
Sumifix Yellow EXF China Indonesia Japan Fakir dyes
Sumifix Red EXF China Indoneshia Japan Fakir dyes
Sumifix Blue EXF China Indoneshia Japan Fakir dyes
Sumifix T. Blue GN China Indoneshia Japan Fakir dyes
Sumifix Red 3BS China Indoneshia Japan Fakir dyes
Sumifix Yellw 3RS China Indoneshia Japan Fakir dyes
Sumifix Yellw GR China Indoneshia Japan Fakir dyes
Sumifix Blue BRF China Indoneshia Japan Fakir dyes
Terasil Yellow - F4G Singapore Swiss color
Terasil Orange - FNR Singapore Swiss color
Terasil Scarlet -FN6G Singapore Swiss color
Terasil Red-FN3G Singapore Swiss color
3. Chemicals:
Chemicals Name Supplier Price (Tk/Kg ) Mode of Action
Kappasol AF 200 Kappachem 371 Antifoam
Kappwet BOS Kappachem 350 Wetting (Detergent)
Kappquest FE Kappachem 147 Sequestering
Kappazone H53 Kappachem 142 Peroxide stabilizer
Kappasoft BD Kappaachem 283 Cationic Softener
Kappasoft SM Kappachem 284 Silicon Softener
Kappatex R98 Kappachem 345 Reducing Agent
Invatex PC CIBA 139 Peroxide Killer
Silvatol FLN CIBA 467 Anti Oil
Cibecel DBC CIBA 176 Leveling gent
Anti per R Gentec 210 Peroxide Killer
Anti per PRB Gentec 211 Peroxide Killer
Eriopon OS CIBA 573 Reducing agent
Invatex AC CIBA 180 Core neutralizing
Cibafix ECO CIBA 396 Fixing
Tinofix FRD CIBA 316 Fixing
Irgasol DAM CIBA 271 Fixing Remover
Cibatex AB45 CIBA 188 High Temp. pH Stabilizer
Univadine DIF CIBA 468 DisperseLevelingAgent
Romapon 173 Dystar 88.53 Anticrease
Uni enzyme 1000 Hunan 290 Enzyme
Acetic Acid Taiwan 89 Acid
Soda Ash China 26 Alkali
Glaubar Salt China 16.28 Electrolyte
Caustic Soda China 52.34 Alkali
Hydrogen peroxide 50% India 45.4 Bleaching Agent
Oxalic Acid 75 Acid

57
Production Sequences &
Operations

58
Sequence of operation:
Lab dip approved
▼
Grey fabric inspection
▼
Batching
▼
Scouring & Bleaching
▼
Enzyming ( If required )
▼
Dyeing
▼
Bath Drain
▼
Cold Wash
▼
Neutral With Acetic Acid
▼
Soaping
▼
Fixing (If required )
▼
Softening
Dyeing Process For Lab
Cotton Dyeing in Lab
Leveling
▼
Dyestuff
▼
Glauber Salt
▼
Acetic Acid
▼
Sample
▼
30 min runtime with temp graduating to 60 c
▼
At 40 c Soda Addition
▼
60 min runtime at 60 c
▼
Cooling
▼
Washing hot & Cold
▼
Neutralizing by acid wash
▼
Soap wash
▼
Drying

59
Polyester Dyeing in Lab
Sample
▼
Neutralizing (by acetic at 50 c)
▼
Cooling
▼
Dispersing agent + Buffer + acetic + Dyestuff
▼
45 min Run at 135 c
▼
Reduction cleaning (Hydrose + Eriopon OS + Caustic)
At 80 c for 45 min
▼
Wash
▼
Chemical Wash
▼
Dry
Dyeing Parameters For Bulk Production:
Process Temp(▫C) pH Time min M : L ratio
Scouring -
98 11.5-12 60' 1:6 or 1:8
Bleaching
Enzyme Wash 55 4.5-5 60' 1:8
Enzyme Deactivation 70 -- 10' --
Reactive Dyeing
60 10.2-10.8 60' 1:8
(Light Shade)
Reactive Dyeing
60 10.9-12 60' 1:8
(Dark Shade)
White Shade 98 10.5-11.5 20' 1:8
Turquish color dyeing 80-90 10.9-12 90' 1:8
Polyester dyeing 130 4-4.5 45' 1:8

60
General process for Pre-treatment
Scouring &
Bleaching: 98▫
C × 60'
60▫
C × 2▫
C/min 80▫
Room
1) Anticreasing
2) Wetting Agent
H2O2
3) Sequestering
Agent
1 2 3 4 5 6
4) Antifoam
5) Stabilizer
Cold Cold
Chemical
Wash:
5' 5'
60▫
C ×
80▫
C × 15'
Room
Cold Cold
1) Oxalic Acid 5'
5'
1 2
2) Peroxide Killer
Bio Polishing/Enzyme Wash:
70▫
C × 10'
55▫
C × Cold Cold
PH
= 4.5-5
1)Acetic Acid
5'
5'
2)Bio-Polish
Dyeing1 Bath Preparation2 :

61
General process for Dyeing
- Auxiliaries are added at 50° C
-Salt added by dosing system (time: 10-20')
- pH maintained at 6.5-7
-Color dosing at 6O° C for 20'
Exhaustion & Fixation:
-After 30' soda ash added by dosing for 30-35'
-pH checked & maintained at 10.5
-Dye bath is kept at 60° C for 40-60'
-After every 10' the sample is checked fixation occurs during this time.
-Rinse for 10' & the bath is drained.
Neutralization:
-The material should be neutralized to remove alkaline condition at room temperature by
acid wash for 15 min & rinsing will be carried on for 10 min.
Soaping:
-Then soaping agent is added & temperture raised to 90°-100°C for 10 min.
-The bath is cooled 7 rinsed for 10 min.
-Dye bath temperature then cooled to 60° C.
Softening:
Softener is applied to soften the fabric as well as it improves the hand feel. The material is
treated at 60°C for 20 mins. Then rinsing again & material unload.
Procedure:
At first the bath is set at 50° C & take the right volume of water in the dye bath.
▼
Required amount of wetting agent is added.
▼
Caustic soda is added & second heat command 60°C & stabilizer is added also.
▼
H202 is dosed & 10' runs.
▼
Temperature raised to 100° C & run the material for 30'
▼
Cooling the bath at 75°C & bath is drained.
At 90° C the material is run for 15 mins
▼
Cooling the bath to 75°C to darin
▼
Add Acetic Acid to neutralize the whole bath of fabric & run time is 20'
▼
Rinse the fabric for 5' & bath is drained.
▼
New water from reservoir is taken & pH should be 4.5-5.
▼
Enzyme is injected to the bath. Run time is 60' at 55°C

62
▼
Temp. raised to 70° C & run time 10' & then drain
▼
Again new water is taken & dosing of glaubar salt for 20' & pH should be
check (pH =7)
▼
Color dosing for 30' at 50°C
▼
Soda is added by dosing for 40'at 50°C
▼
Then raise the temp. & run the fabric for 35-60'.At this time after every 10' the sample is
checked.
▼
Rinse the material for 10' & bath is drained.
▼
At room temp. acid treatment is done for 20'& rinse the material for 5'
▼
Soaping is done at 90°C for 10 min & bath is drained.
▼
Fixing agent is added at 50° C & run time is 20' & bath is drained
▼
Softening is done at 60° C for 20'& bath is drained.
▼
Finally, the fabric is unloaded.

63
Process for White Shade:
At first Scouring bleaching chemicals are added to the bath & they are treated at 98°C for 60'
▼
Temp. lowered at 80°C & OBA is added.Run time is 10'.
▼
Temp. raised to 98° C & Run time is 20'.
▼
Then enzyme treatment is applied & then softening occurs
Dyeing Curve:
60▫
C × 60'
Cold
Room temperature 1) Auxiliaries
Normal Hot: 2) Salt
3) Color dosing
(20-30')
Acetic5'
5' 5'
▫
1 2 3 4 60 C × 10'
Soap wash (Hot): 20'
90▫
C
80▫
C
60▫
C
Soaping
chemical
Fixing (if dark shade):
50▫
C ×
20′
Fixing agent
Softening:
40▫
C ×
Softener
&

64
Some Dyeing Recipe used in Bulk dyeing
process
Knit Dyeing Recipe#1
Color : 10-100-White
M: L : 1:8
Material Type : 100% Cotton
Auxiliaries/Chemicals Amount Amount
(g/l) (%)
SCOURING & BLEACHING
Kappasol AF -2000 (Antifoam) 0.15 -
Polymer ECO (Anticreasing) 0.50 -
Tino Wine (Multi Functional) 3.00 -
Caustic 2.00 -
H2O2 (50%) 8.00 -
PHYSICAL BLEACHING
Bluton BVB (OBA) - 0.23
NEUTRALIZATION
Oxalic Acid 1.00 -
Denquest HYN (Sequestering) 0.20 -
ENZYMATIC CLEANING
Acetic Acid 0.80 -
Unizyme 1000L (Enzyme) 0.60 -
FINISHING
Softener E-31 - 10

65
Color : (Pink)
M: L : 1:7
Auxiliaries/Chemicals Amount Amount (%)
(g/l)
Kappawet BOSS (Detergent) 0.60 -
Fistol AWP (Stabilizer) 0.40 -
Caustic 1.50 -
Soda 0.80 -
H2O2 (50%) 2.50 -
NEUTRALIZATION
Oxalic Acid 0.50 -
ENZYMATIC
CLEANING &
PEROXIDE
REM OVAL
Antiper R (Peroxide Killer) 0.50 -
Acetic Acid 0.80 -
DYEING
BATH
Kappasol AF -2000 (Antifoam) 0.10
Polymer ECO (Anticreasing) 0.50
Albatex – DBC (Levelling) 1.00
Bezactive Yellow – SMAX -
Bezactive Red – S3B – 300% -
Glauber Salt 30
Soda 10
NEUTRALIZATION
Acetic Acid 0.50
SOAPING
Kappaquest A41 (Soaping) 0.50
AFTER TREATMENT
Softener SA -1000 -
Invatex –AC (Core Neutralizer) 0.40
-
-
-
0.182
0.28
-
-
-
-
10
-

66
Color : Gris Moyen
M: L : 1:8
(g/l) (%)
Caustic 1.50 -
Soda 0.80 -
H2O2 (50%) 2.50 -
NEUTRALIZATI
ON
Oxalic Acid 0.50 -
ENZYMATIC CLEANING &
PEROX
IDE
REMOVA L
Acetic Acid 0.80 -
DYEING BATH
Biavin – 109 (Anticreasing) 0.50 -
Albatex – DBC (Levelling) 0.50 -
Remazol Ultra Yellow RGB - 0.8060
Remazol Ultra Red
RGB - 0.6160
Remazol Navy RGB - 1.060
Glauber Salt 50 -
Soda 15 -
NEUTRALIZATI
ON
Acetic Acid 0.50 -
SOAPING
Kappaquest A41 (Soaping) 1.00 -
AFTER
TREATMENT
Softener SA -1000 - 1
Invatex –AC (Core Neutralizer) 0.20 -

67
Knit Dyeing
Recipe#4
Color : 902-Noir (43517) Black
M: L : 1:8
(g/l) (%)
SCOURING &
BLEACHING
Caustic 0.30 -
H2O2 (50%) 2.00 -
2.00 -
NEUTRALIZATIO
N
Acetic Acid 0.30 -
ENZYMATIC
CLEANING
Acetic Acid 0.80 -
DYEING BATH
Reactive Yellow 3R - 1.10
Sunfix Red MF –
3BD - 0.550
Reactive Starfix Black - GR - 7.0
Glauber Salt 80 -
Soda 20 -
Caustic 2 -
NEUTRALIZATIO
N
Acetic Acid 1.00 -
SOAPING
AFTER
TREATMENT

68
Knit Dyeing
Recipe#5
Color : Royal blue
M: L : 1:8
Auxiliaries/Chemical
s Amount Amount
(g/l) (%)
SCOURING &
BLEACHING
Caustic 2.00 -
Soda 1.00 -
H2O2 (50%) 3.00 -
NEUTRALIZATI
ON
Oxalic Acid 0.50 -
ENZYMATIC CLEANING &
PEROX
IDE
REMOVA L
Acetic Acid 0.30 -
DYEING BATH
Dychufix Yellow -3R-XF 150% - 0.02
Dychufix Red – EC - 0.05
Remazol Brilliant Blue RSPL - 1.60
Glauber Salt 40 -
Soda 15 -
NEUTRALIZATI
ON
Acetic Acid 0.80 -
SOAPING
Fistol RS (Soaping) 0.50 -
AFTER
TREATMENT

69
Color :
Teal
(Turquoise)
M: L : 1:8
(g/l) (%)
Caustic 0.40 -
Soda 1.00 -
H2O2 (50%) 3.00 -
NEUTRALIZATI
ON
Oxalic Acid 0.50 -
ENZYMATIC CLEANING & PEROX
IDE
REMOVA L
Acetic Acid 0.80 -
DYEING BATH
Dychufix Yellow - 4GL - 0.1680
Synozol Turq. Blue HF-G 266% - 1.40
Synozol Blue K-BR - 0.75
Glauber Salt 40 -
Soda 15 -
NEUTRALIZATI
ON
Acetic Acid 0.80 -
SOAPING
AFTER TREATMENT

70
Color : 09-090 Black
M: L : 1:8
Material Type : CVC (60-40)
(g/l) (%)
SCOURING &
BLEACHING
Kappavon CL (Anticreasing) 0.70 -
Invatex –CRA (Detergent) 0.60 -
Fistol DM 0.30 -
Caustic 2.25 -
H2O2 (50%) 2.00 -
NEUTRALIZATION
Acetic Acid 0.80 -
ENZYMATIC
CLEANING
Acetic Acid 0.80 -
POLYESTER PART
DYEING
Fistol DM (Sequestering) 0.50 -
Univadine DIF (Dispers Levelling) 1.00 -
Albatex – AB45 (Acid Buffer) 2.00 -
Acetic Acid 0.30 -
Terasil G. Yellow W -3R - 0.025
Terasil Red WRS - 0.15
Terasil Black WNS - 2.50
REDUCTION
CLEANING
Hydrose 3.00 -
Caustic 2.00 -
Eriopon OS (Dispers Soaping) 2.00 -
NEUTRALIZATION
Acetic Acid 0.80 -
COTTON PART DYEING
Fistol DM (Sequestering) 0.50 -

71
Reactive Yellow 3R - 0.28
Sunfix Red MF – SB - 0.62
Novacron Super Black G - 4.95
Glauber Salt 80 -
Soda 20 -
Caustic 01 -
NEUTRALIZATION
Acetic Acid 0.80 -
SOAPING
Acetic Acid 0.80 -
Color : Aqua (5186-C)
M:L : 1:10
Material Type : Viscose
(g/l) (%)
Viscocolor (Multifunctional) 4.00 -
Felosan NOF (Detergent) 0.50 -
Kappaquest FE (Sequestering) 0.20 -
0.30 -
PEROXIDE
REMOVAL
Invatex-PC (Peroxide Killer) 1.50 -
Acetic Acid 0.30 -
DYEING BATH
Vibatex –HKN 0.50 -
Cibacron Yellow H4GN - 0.036
Cibacron Navy H2G - 0.14
Synozol Turq. Blue HF-G 266% - 0.70
Glauber Salt 30 -
Soda 10 -

72
NEUTRALIZATI
ON
Acetic Acid 1.20 -
SOAPING
Machine Wash
Recipe:
-First of all these two chemicals are taken & treated in normal temperature for 30 min.
Soda ash =
0.5
g/L
Bleaching powder =
0.5
g/L
Then Direct drain is done.
for white - - -
First of all these two chemicals are taken & treated in normal temperature for 30 min.
Soda ash =
0.5
g/L
Bleaching powder =
0.5
g/L
Then Direct drain is done.
-After that these two chemicals are taken & treated with fabric at 98°C for 60 min.
Hydrous =
1-2
g/L
Caustic Soda =
1-2
g/L
Add hydrose (6 g/L) & caustic Soda (6 g/L)
▼
Run 20' at 110° C
▼
Run 10' at 95° C
▼
Run 10' at 80° C
▼
Run 10' at 60° C
▼
Run 10' at 40° C
▼
Drain

73
pH checks in different point in dyeing processes: (Cotton)
pH checks in different point in dyeing processes: (Polyester)

74
Quality Testing, Control &
Assurance System

75
Quality Assurance System
The quality assurance department is assigned to maintain consistently uniform quality of
the material in process & various stages of its manufacturing.
Objects of quality control
1.Research
2.Selection of raw material
3.process control
4.Process development
5.Product testing
6.Specification test
Quality Assurance Procedure:
Knit Concern Ltd. assures the quality of their products in the following three steps:
1. In laboratory
2. In dyeing section
3. In finishing section
The quality assurance procedures are described below:
In Laboratory:
 Swatch card from buyer according to their requirement is received.
 Recipe prediction for sample dyeing using CCMS.
 Sample dyeing until matching with the swatch card. Acceptable color difference is
less than 1.
 If matching is OK, then it is sent to the buyer for approval.
In Dyeing section:
 After approval form the buyer, sample dyeing is done in dyeing m/c, in dyeing
shed & again matched with the approved sample.
 If result is OK, then balk production is commenced.
 During dyeing process, before the final acid wash, samples are taken and checked
for accurate shade matching.
 After dyeing sample is collected & matching is done.
 Rubbing and wash fastness tests are carried out.
In finishing section:
 Correctly dyed, after treated & matched fabrics are allowed for finishing.
 By using a series of finishing machines correct width, softness & appearance are
maintained according to requirements.
 Then sampling is done several times to test GSM, Shrinkage & fastness properties.
 Finally, fabric is inspected & prepared for delivery.
In KCL following flow diagram is followed-

77
Physical test of fabric:
-Fabric weight
-Dimensional Changes in lengthwise
-Dimensional Changes in widthwise
-Seam Slippage
-Spirality test
-Pilling Resistance
-Softness test
-Hairiness test
Chemical test of fabric:
- Fastness to rubbing
- Fastness to washing
- Fastness to perspiration
Besides these, for the best qualified production these Chemical Test should be performed
-Fastness to light
-Fastness to heat
-Fastness to sea water
-Fastness to chlorinated water
-Fastness to actual laundering
Problems Encountered in Dyeing
 Uneven Dyeing

1. It can be caused due to rapid addition of dyes and chemicals. For this purpose, the
dosing of soda ash should be maintained properly.
2. Pressure difference.
3. Over loading in the m/c.
4. Yarn lot mixing.
5. Improper control of temperature.
6. Less amount of leveling agent.
7. Improper pretreatment.
 Rope to Rope Uneven Shade

1. Improper rope length in each chamber.
2. Improper fabric flow speed in each nozzle.
 Off Shade

1. Improper M: L ratio.
2. Lower amount of auxiliaries.
3. Improper mixing of dyestuffs.

78
 Dye Spots
This is most common fault caused by operator not correctly mixing and thoroughly
dissolving dyestuffs in the right amount of water
 Batch to Batch Shade Variation
If any of parameters of dyeing are changed then it will produce problems in batch to batch
consistency. In order to avoid this, defect the following steps should be followed-
1. Maintain the same liquor ratio.
2. Check that the fabric has the same dye affinity.
3. Use the same standard program procedures for each batch.
4. Make sure that the operators add the right batch of chemicals at the same time &
temperature in the process.
5. Check the water supply daily especially ph
, hardness & Na2CO3 content.
 Crease Mark
Crease marks are produced due to the lower concentration of anti-creasing agent and
improper cooling rate (defective cooling gradient). This is encountered by increasing the
concentration of anti-creasing agent and proper adjustment of cooling rate.
 Running Marks
Running marks are frequently related to the material construction and are caused by poor
opening of the fabric rope.
1. Reducing the machine load and running at a slightly higher nozzle pressure, or
using the next largest available nozzle size, may also help.
2. Either presetting or pre-relaxation of the fabric before dyeing can avoid this
problem.
3. Running and crack marks can also be a result of incorrect process procedures. A
higher fabric speed, combined with slower rates of rinse and cooling will often correct the
problem.
4. Care should be taken to check that bath draining temperatures are not very high
especially viscose blends are involved.
5. Shock cooling of static material will also cause crack marks.
 Intensive Foaming
In case of intensive foaming, which is caused when, the pumps try to pump a mixture of air
and water. This resets in the loss of nozzle pressure & floating of flake. If the foaming is severe
it is better to drop the bath & restart the process, after adding an anti-foaming agent to the
new bath.
 Patchy Dyeing
It is caused, if dye solution is not correct and also scouring is improper.

79
 Miscellaneous Problems
Batch to batch processing may vary due to the improper calculation of dyes and chemicals
and improper strength of salt soda and H2O2 etc. Beside hardness of water and caustic may
lead to an improper shade.
Finished fabric Inspection:
The final product should pass against the norms given by the buyer. The following tests are
done-
-Shade check
-GSM test
-Width or diameter test
-Shrinkage test
-Crocking test
-Pilling resistance test
-Color fastness to test
-Color fastness to perspiration
-Dimensional stability
For final inspection, Inspection table & Inspection m/c is used.
The 4-point system is given below-
Size of Defect Penalty point
Less than 3 inches 1
3-6 inches 2
More than 6- 9 inch 3
More than 9 inch 4
Size of holes & openings-
1 inch or less 2
More than 1 inch 4
Some general rules of the inspection are-
1. Not 1 metre of cloth is penalized more than 4 points.
2. Cloth is inspected on face side only unless specified.
If the total defect parts per 100 yards of fabric are 40 or more the fabric will be rejected.
But it may be changed according to buyer’s requirements
Shade check:
The shade achieved is to be checked several times while in process & at finished state to
ensure the customers demand under recommended light source. Generally, the shade is
checked at the following stage
-After dyeing
-After drying
-After trial for finishing
-After finishing

80
During dyeing period in QC there is a shade matching sequence:
Scoured sample
▼
Enzyme sample
▼
Salt Sample
▼
Soda sample (after 10 min)
▼
BD sample (60▫C × 20 min)
▼
Normal hot sample
▼
Acetic acid sample
▼
Chemical hot sample
▼
Softener sample
For this the following equipment are used:
1.Verivide light box
Manufacturer: Cundy building, frog island Origin: England
Light Source:
D-65 (artificial day light)
TL-84 (Shop light)
F (florescent light)
UV (Ultraviolet Blue light)
Procedure of GSM measurement by GSM cutter:
1. Cut the fabric with the G.S.M cutter.
2. Weight the fabric with the electric balance.
3. The cut sample is 100 sq.cm. The weight of the cut sample is multiplied by 100.
4. The result is the G.S.M of that particular fabric.
Suppose,
The weight of the fabric is 2.51 gm. That means the G.S.M of the fabric is 251 gm.
Specification of GSM cutter:
Name: G.S.M CUTTER
Manufacturer: James H. Heal & Company limited.
Origin: England
Width or diameter test:
After finishing the fabric diameter or width is measured by a measuring tape. If the width is
more or less compactor is used to set the required width If width is more, then lengthwise
tension is increased and if width is less it is increased by shape.
Shrinkage test:
The shrinkage properties are one of the most important properties to be checked for
the knitted fabric

81
For this the equipment used:
Name: Electrolux Washcator
Manufacturer: James H. Heal & Company limited.
Origin: England
There is a water label in m/c. Automatically water entered up to this label Then detergent
(10 gm) is added for per garment the useable program for Washcator are
Temperature (▫C) Time (min)
40 60
45 64
50 81
The washing methods:
Based on ISO 6330 ,3759, 5077.
Rubbing fastness test:
Rubbing fastness is tested by crock meter.
Name: Electronic Crock meter
Manufacturer: James H. Heal & Company limited. Origin: England
Test method: ISO 105 x 12. Dry & Wet rub is including in this method.
Pilling Resistance Test:
Name: ICI Pilling Test
Manufacturer: James H. Heal & Company
Ltd. Origin: England
Test method: EN ISO 12945-2
Description: For wool / wool Blends / Elastane Blends -
7200 revolutions
-1 revolution / sec
For other type of fabric
-14400 revolution
-1 revolution / sec

82
Fastness Testing
 Color Fastness to Wash:
"Color Fastness " is the resistance of the color to fade or bleed by washing, light, water dry-
cleaning chlorine perspiration & ironing.
Test method: ISO 6330,3759,5077.
Equipment Used:
Rota Wash
M:L = 1:50
Multifilament Size = 10*4 cm
Sample Size = 10*4 cm
Temp. = 50°C
Time = 30 min
Chemical Used: Detergent ECE (4 g/1), Na-per borate (1 g/1)
Shade change is measured by color change scale & staining scale.
 Color Fastness to perspiration:
Test Method: ISO -105 E04
Temp = 37 +2°C
Time: 4 hr.
Dry Temp = 60° C
M:L = 1: 50
Wet Time: 30 min
Multifilament Size = 10*4 cm
Sample Size = 10*4 cm
pH :8-5.5
Chemical Used: Alkali (g/l) Acid (g/l)
1-histadine mono hydrochloride 0.5 0.5
Sodium Chloride 5 5
Di-sodium Hydrogen Orthophosphate 2.5 2.2
pH 8 5.8
Distilled water 1000 ml 1000 ml
Dimensional Stability:
This is checked by spirility test. Equipment Used:
Quick wash m/c
Template Size:
- 38 "x 38"
- 25" x 25"
Temp.= 50° C
Time = 12 ' (Wash & Dry)
A B
D C

83
2*(AC*BD)
Spirility (%) = × 100
(AC + BD)
The standard Spirility % is 5% after the domestic wash.
REMARK:
In this modern world, the buyer requirement is increasing day by day. And they are
conscious about Quality of product more to fulfil this QC department has a lot to do Online.
QC also check the following fault- Hole, Fly yarn, Dye stain, Chemical Stain, Uneven shade,
Meter to meter Variation, compactor Crease, Patchy dyeing, Yam contamination, Sinker
mark, dyeing Crease etc.
So, QC department is very much important in dyeing section.

85
Maintenance of Machinery:
Maintenance of machinery is very essential mechanical effort for achieving
smooth running of different machines. Maintenance is a process by which equipment is
looked after in such a way that trouble-free services and increased machine life can be
ensured and specific product quality required by the customers is sustained. On time
maintenance increase m/c lifetime & ensures trouble free services.
2 types of maintenance are done:
1. Break down maintenance
2. Routine maintenance
Maintenance
Routine Maintenance Break Down Maintenance
Mechanical Maintenance Electrical Maintenance Mechanical Maintenance Electrical Maintenance
1. Break down maintenance: Break down maintenance is done instantly when
problem arises in machine. In this case, repairs are made after the equipment is out of order
and it cannot perform its normal functions.
2. Routine maintenance: After a particular period of operation, the machines are
cleaned & reordered, that is routine or schedule maintenance. The maintenance department
does it once in a month. Schedule maintenance varies, time in time & also depends on
situation according to types of machines, because maintenance is directly related to
production.
Most of the time, all the screws, nuts, bolts & levers are checked, lubrication is also done.
Workers inform about the problem areas of the machines. Depending on their
information maintenance is done. Maintenance engineer analyze the records and take
steps according to requirement.
Routine:
Maintenance is a necessary task in any industry. But the degree and interval of
maintenance is dependent upon the age of the machineries. Landmark Textile Mills Ltd. has
relatively new machineries, which are very modern and state-of-the-art. Due to this reason
a relatively less amount of maintenance is needed to be carried out in Landmark Textile
Mills Ltd. Never-the-less, routine maintenance of the machineries of the dyeing section is
carried out once a week.
As the dyeing section remains closed in Friday, the routine maintenance is carried out in
Friday. As for break down maintenance (very few break down cases occur), proper steps
are taken to rectify the problem.

86
Manpower Setup for Maintenance:
Post Number of Employees
Mechanical Engineer 1
Electrical Engineer 2
Mechanical Fitter 1
Electrical Supervisor 1
Asst. Mechanic 2
Electrician 1
Asst. Electrician 2
Maintenance Procedure:
Maintenance: Mechanical
Machine: Dyeing Machines
Sl. No. Item needed to be checked & Serviced
1. Greasing of the winch bearing
2. Complete cleaning of machine
3. Cleaning of drain valves, replace seals if required
4. Checking of air supply filter, regulators, and auto drain seals
5. Cleaning of filter elements
6. Greasing of unloading roller bearings
7. Checking and cleaning (if required) of addition tank level indicator
8. Checking the oil level of pump bearing and refill if required
9. Checking the function of heat and cool modulating valves
10. Checking of all belts and belt tension
11. Check circulation, reel and other pumps
12. Checking of all door seals

87
Machine: Stenter Machine
1. Removal of gas burnt deposits from chains
2. Checking of gas burners
3. Cleaning of softener application unit
5. Checking and cleaning of steam pipe lines
4. Checking and cleaning of gas pipe lines
5. Grinding of fabric gripping pins
6. Cleaning of ventilation duct
7. Cleaning of m/c cabinet
8. Checking of motors
Machine: Dewatering Machine
Sl. No.
1.
2.
3.
Item needed to be checked & Serviced
Cleaning of softener application unit
Checking of rotating device of rotating trolley unit
Checking of pneumatic pressure valves
4. Checking and replacement (if necessary) of rubber pads of stretching unit
5. Checking of plaiting device
6. Checking of speed regulating unit
Machine: Tensionless Dryer
1. Checking of gas pipe lines
2. Checking of gas burners
3. Checking of belt conveyor system

88
6. Cleaning of ventilation duct
7. Cleaning of m/c cabinet
Machine: Compactor Machine
1. Checking of Steam pipe lines
2. Checking of pneumatic pressure valves
3. Checking of belt conveyor system
6. Checking and replacement (if necessary) of compacting shoe
7. Cleaning of compacting shoe
Machine: Raising Machine
1. Checking of Gearing system and replacement of faulty gears
2. Cleaning of fiber deposits from the pile and counter pile rollers
3. Grinding of pins of pile and counter pile rollers
4. Lubrication of gearing system
Machine: Boiler
1. Checking of gas pressure and gas supply line
2. Dosing of softening chemicals to supply water
3. Checking of all steam lines
4. Cleaning of burner tank (after six-month interval)
5. Checking and replacement of valves

89
6. Cleaning of feed water tank
7. Checking and replacement of filters
8. Cleaning of sight glass
Maintenance : Electrical
SL NO. Items needs to be checked & serviced
1 Check main panels
2 Check panel cooling fan & clean its filter
3 Clean main pump inverter & its cooling fan
4 Check all circuit breaker, magnetic conductors & relays
5 Check current setting of all circuit breaker & motor over load
6 Visual checking of all power & control cables
7 Check ail motor’s terminals
8 Check & clean fluff & dirt at all motor fan covers
9 Check DC drive of kneel motors
10 Check all pressure switches
11 Check calibration of main vessel & all addition tank
12 Check all signal isolators
13 Check setting & operation of lid safely switches
14 Check setting of tangle sensors
15 Check all pneumatic solenoids
16 Check all indicating lamps
17 Check calibration of heating/ cooling modulating valve
18 Check all on/off switches
Maintenance Tools and Equipment:
Sl. No. Maintenance tools/equipment
1. Adjustable wrench
2. Pipe Spanner
3.
Spanner
4.
Socket spanner
5. Hammer
6. Screw driver
7. Punch
8. Lock opener
9. Hack saw
10. Outside calipers
11. Inside calipers
Functions
Used for setting nut & bolts
For pipe fitting
Fixed Spanner for nut & bolts
fitting
Handle system for nut & bolt
fitting
To apply load where required
To release any screw
Used to fit any worn-out shaft
To open the clip of bearing
To cut any metallic thing
To measure outside dia
To measure inside dia

90
12. Slide calipers To measure very small dia
13. Vernier scale To measure very small dia
14. Chain ton To lift heavy load
15. Welding machine To join metallic parts
16. Grinding machine To make the smooth fabrics
17. Tester To test electric circuit
18. Pliers To grip anything & cut anything
19. Avometer/Voltmeter To measure voltage
20.
Steel tape
To measure length, width &
height
21. Chisel To cut any metal
22. File To smooth the rough surface
Remarks:
The maintenance department of Knit Concern Ltd. is well equipped. It has
sufficient maintenance manpower including mechanical and electrical engineers. They
perform maintenance tasks of the machines during the holidays and vacations. Otherwise,
they perform breakdown maintenance, which as stated earlier is very rare in Knit Concern
Ltd. To increase the lifetime of the machineries and ensure the proper running of the
machines, the task of this department is very important.

93
Product mix:
- 100 % cotton
- CVC (Chief Value Cotton) (60/40)
- Grey melange
* 15 % Viscose & 85 % Cotton
- Ecro melange (2%)
- Camel melange (1%, 2%)
- PC (52/48)
-Sewing thread.
-Poly acrylic threads (NOT 100%).
 Project Cost: 50 core Taka (Approximately).

 YARN DYEING SECTION:
AREA: 1 LAKH sq. fit. Floor: MULTI-STORED FLOOR (25,000 sq.ft/floor).
PRODUCTION: 15 TONS (Approximately) . It has two lifts, two cranes of capacity=10
tons. There is a Bas Bar (have no wire) system to facilitate production.
Different Departments:
Production Oriented Department:
 Yarn store

 Planning & Control
 Batching
 Chemical store
 Winding section
 Dyeing Section
 Finishing Section
 Dyeing lab section
 Wet lab
 Quality Control
 Maintenance
 Utility
 Water treatment plant
 Effluent treatment plant

94
Supporting department:
- Procurement
- Merchandising
- Marketing
- IT
- HRD
- Finance & accounting
- Medical
- Personnel Administration
- Security
Remarks:
It's a wonderful project. Though it's a new project but profitable for its strong management
the main drawback was there is no Effluent Treatment but within some days The Effluent
treatment plant will be completed.

95
Machines & Different Sections

96
Winding Machine Specification
SOFT WINDING SECTION
Total no. of m/c : 07
Total no of spindle : 510
Machine Specification
M/c identification : 01 Origin : Switzerland,
Brand : SSM EU
Origin : Switzerland, Type : PS6-W
EU M/c no : 883.0429/06
Type : TW2-W Manufacture year : 2007
M/c no : 856.0130/06 U : 400V
M/A No : 38937 Imax : 32A
U : 400V F : 50Hz
Imax : 38A No. of spindle : 60
F : 50Hz
No. of spindle : 78
M/c identification : 05
Brand : SSM
Origin : Switzerland,
Brand : SSM EU
Origin : Switzerland, Type : PS6-W
EU M/c no : 883.0429/06
Type : PS6-W Manufacture year : 2007
M/c no : 883.0429/06 U : 400V
Manufacture year : 2007 Imax : 32A
U : 400V F : 50Hz
F : 50Hz
No. of spindle : 60
Brand : FADIS
Origin : Italy
Brand : SSM Type : SINCRO-T-FT.
Origin : Switzerland, P300
EU Plate no : G0022
Type : PS6-W Manufacture year : 2008
M/c no : 883.0429/06 Power Kw : 12
Manufacture year : 2007 Volt : 440
U : 400V Ampere : 16
F : 50Hz
No. of spindle : 60
Brand : FADIS
Origin : Italy
Brand : SSM Plate no : G0022
Manufacture year : 2008

97
Power Kw : 12
Volt : 440
Ampere : 16
No. of spindle : 9
Controlling Parameters
Traverse Length : For cotton-generally 14.7 cm
Maximum 15 cm
For polyester-generally 14 cm
Weight of yarn in each package : For cotton-generally 1100 gm
For polyester-generally 800gm
Types of winding : 2 types-DIGI & Precision
Length of yarn in each package : Depends on yarn count
Feeder : In SSM-10 to 35 (increases with the fineness
of yarn)
In Fadis-generally 30% (independent of
count)
Tension : Decreases with fineness of yarn
Diameter of full package : generall-16 cm
maximum-17 cm

99
Hard Winding Section
Total No. of Machine : 5
Machine Specification
M/c identification : 01 Type : CW2-W
Brand : SSM M/c no : 863.0029/07
Origin : Switzerland, U : 400V
EU Imax : 28A
Type : CW2-W F : 50Hz
M/c no : 863.0029/07 No. of spindle : 96
U : 400V
M/c identification : 04Imax : 28A
F : 50Hz Brand : FADIS SPA
No. of spindle : 96 Origin : Italy
Type : SINCRO-T-
FT/RT
Brand : SSM Manufacture year : 2008
Origin : Switzerland, Power Kw : 12
EU Volt : 440
Type : CW2-W Ampere : 16
M/c no : 863.0029/07 No. of spindle : 96
U : 400V
M/c identification : 05Imax : 28A
F : 50Hz Brand : FADIS SPA
No. of spindle : 96 Origin : Italy
Manufacture year : 2008
Power Kw : 12
Brand : SSM Volt : 440
Origin : Switzerland, Ampere : 16
EU No. of spindle : 96
M/c identification : Sewing Thread Winding
Brand : HACOBA
Origin : Switzerland,
Year : 2007
U : 400V
Imax : 68A
F : 50-60 Hz
No. of spindle : 12

100
Controlling Parameters
For m/cs 1-5
Winding speed : 800 m/min
Initial Traverse : 157 mm
Tension : 5-6 gm
For Sewing Thread winding m/c
Winding speed : 1000 m/min
Traverse length : 105 mm
Yarn length : 4000m
Full bobbin dia : 70mm

101
Yarn dyeing Laboratory
 Main Responsibility

 Accepting the ‘Swatch’ from the buyer and analyze the color & Dyes.
 Preparing the Recipe accurately matching the required color.
 Storing & maintain the dyes to be used for dyeing.
 Producing self-shades & storing it into the computer.
 Record & analysis of chemicals & dyes quality.
 Making plans for bulk dyeing.
 Following the color coding system given by the distinctive buyer & also prepare own
color bank.
 Testing the dyed goods.
 Lay-out

102
 List of Machines in Yarn Lab

1. Sample yarn dyeing m/c
2. Sample dryer
3. Data color Spectrophotometer
4. Auto Lab dispenser
5. Computer
Auto Lab Dispenser
Flow of work:
Swatch from buyer/merchandiser
(Contains: fabric construction-gsm-color name-color code-style)
Shade matching by lab works
Shade submission
(Sample match A, B, C)
Approved Rejected
Recipe delivered for bulk-productio

103
Dyeing Machine Specification
 Brand: Fong’s International co.
 Made in Hong-Kong, China.
Total number of Dying Machine: BULK – 14 SAMPLE – 6
Total Production Capacity – approx. 12~13 tons/day
BULK MACHINE: Brand: Fong’s International co.
Design parameters: (according to layout plan)
Dyeing Machine No-01
M/c No.:all win -53-8A
M/c No.:all win -43-6A CAPACITY:53 KG
CAPACITY:30 KG YEAR OF MANUFACTURE :2007
YEAR OF MANUFACTURE :2007 DESIGN PRESSURE (Kpa):520
DESIGN PRESSURE (Kpa):520 TEMP.(0
C):140
TEMP.(0
C):140 HYDROULIC TEST PRESSURE(kpa):800
HYDROULIC TEST PRESSURE(kpa):800 TEST DATE:2007
TEST DATE:2007 SAFETY VALVE SET(kpa):520
SAFETY VALVE SET(kpa):520
Dyeing Machine No-02 M/c No.:all win -70-9A
M/c No.:all win -53-6A CAPACITY:100 KG
CAPACITY:53 KG YEAR OF MANUFACTURE :2006
YEAR OF MANUFACTURE :2007 DESIGN PRESSURE (Kpa):520
DESIGN PRESSURE (Kpa):520 TEMP.(0
C):140
TEMP.(0
C):140 HYDROULIC TEST PRESSURE(kpa):800
HYDROULIC TEST PRESSURE(kpa):800 TEST DATE:2006
TEST DATE:2007 SAFETY VALVE SET(kpa):520
Dyeing Machine No-03 M/c No.:all win -85-9A

104
CAPACITY:200 KG
YEAR OF MANUFACTURE :2007
DESIGN PRESSURE (Kpa):520
TEMP.(0
C):140
HYDROULIC TEST
PRESSURE(kpa):800 TEST DATE:2007
CAPACITY:200 KG
TEMP.(0
C):140
HYDROULIC TEST
CAPACITY:400 KG
TEMP.(0
C):140
HYDROULIC TEST
CAPACITY:400 KG
YEAR OF MANUFACTURE:
2007 DESIGN PRESSURE
(Kpa):520 TEMP.(0
C):140
HYDROULIC TEST
M/c No.:all win -145-9A.
CAPACITY:400 KG
(Kpa):520 TEMP.(0
C):140
HYDROULIC TEST
CAPACITY:600 KG
(Kpa):520 TEMP.(0
C):140
HYDROULIC TEST
CAPACITY:600 KG
TEMP.(0C):140
HYDROULIC TEST
CAPACITY:800 KG
TEMP.(0
C):140
HYDROULIC TEST PRESSURE(kpa):800
TEST DATE:2007
Dyeing Machin No-13
CAPACITY:1000 KG
TEMP.(0
C):140
TEST DATE:2007
CAPACITY:1600 KG
TEMP.(0
C):140
TEST DATE:2007
SAMPLE MACHINE
Dyeing Machine No-01 (2 m/cs – a,b)
M/c No.: MICROwin -1
CAPACITY: 300 gm.
YEAR OF MANUFACTURE: 2007
DESIGN PRESSURE (Kpa): 520
TEMP. (0
C): 140
HYDROULIC TEST PRESSURE (kpa): 800
TEST DATE: 2007
SAFETY VALVE SET (kpa): 520
M/c No.:LAB win 12-K1.
CAPACITY: 14gm
TEMP. (0
C): 170
TEST DATE: 2007
M/c No.: LAB win 12-K1.
CAPACITY: 14gm
TEMP.(0
C):140
TEST DATE: 2007
CAPACITY: 7 kg

105
TEMP. (0
C):140
TEST DATE: 2007
CAPACITY: 7 kg
(Kpa):520 TEMP.(0
C):140
HYDROULIC TEST PRESSURE (kpa):
800 TEST DATE: 2006
# DETAILED CAPACITY OF DYEING MACHINES:
M/C CAPACITY NO. OF NO OF PACKAGE PER TOTAL NO. OF TOTAL WEIGHT
CARRIER CARRIER PACKAGE (Kg)
(each 1.1 kg)
1600 108 12 1296 1425
1000 69 12 828 910
800 54 12 648 715
600 54 9 486 534
400 36 9 324 356
200 18 9 162 178
100 9 9 81 89
60 6 8 48 53
50 6 6 36 39
30 4 6 24 26

107
Working Mechanism of Dyeing m/c
Type of Dyeing m/c: Fong’s High Temperature High Pressure Package dyeing m/c.
Package type: Loosely wound Cone (from soft winding)
 Main Parts:

1. Main vessel: -large vertical metal alloy vessel, specially designed to
withstand high temperature & pressure.
-connected with several lines & pipes from different sections like from auto
dosing, manual dosing tanks, steam lines, exhaust pressure line etc.
-vessel contains number of spindles & package carriers (as shown in figure
below)
2. Perforated bobbins & mechanical load-unload system:
The soft wound packages are wound into a perforated steel bobbin tube by which the
liquor can be spread from inside the bobbins. The figure shows related operations.

108
3. Preparation tank & manual dosing tanks:
-One large preparation tank, which is used to transfer the liquor from the main
vessel when necessary for e.g. during shade checking. It’s also used for mixing salts or soda solution
directly from auto-dosing lines. It contains separate steam & cold water lines.
-Two small separate dosing tanks used for optional purpose & for dyes dosing.
4. Motors & Valves:
- Different types of motors used in dyeing m/c. For example,
1. Stirrer motor.
2. Circulation pump.
3. feed-pump.
4. Dosing pump.
5. Preparation tank pump.
- Different types of valves are used in the dyeing m/c. for example,
1. steam inlet
2. water inlet
3. cooling water inlet
4. overflow
5. drain
6. condensate outlet
7. main fill
8. exhaust valve

109
fig: a schematic view of vertical yarn dyeing m/c
5. Heat-exchanger & Liquor Circulation System:
Heat-exchanger is the most important part of dyeing machine. Here, two
separate inlet & outlet line of steam & cold water. These are used alternatively for heating & cooling
the liquor temperature.
Liquor is pumped & sucked by the main circulation pump alternatively.
Thus, the heated or cold liquor circulates from ‘in-out’ or ‘out-in’ path through the perforated
packages alternatively. These ensure maximum contact of the liquor with the substrate. This
alternate process is done by a special type electronically controlled actuator

110
Auto Dosing System
- All the chemicals required for dyeing operation are mixed in the dye bath
automatically from “auto dosing system”
- It is an integrated system controlled by computer which involves all the
calculation required for exact amount of chemicals needed for dyeing a
particular recipe.
- No. of tanks: - 17
Two large tanks (SILO) for Salt & Soda – Soda tank: 16 ton
Salt tank: 31 ton
Salt & Soda are made solution in the mixing tanks before storing into Silos. There are 3 mixing tanks-
a) Common mixing tank for both soda & salt – 1000 li.
b) Salt mixing tank – 1000 lit – 1.5 lit water per kg of salt.
c) Soda mixing tank – 1000 lit – 2.5 lit water per kg of soda

111
Chemical Tanks -total: 15
a) 14000 lit – 1 tank – Hydrogen Per Oxide Solution
b) 2000 lit – 2 tanks – Acetic Acid & Softeners
c) 1200 lit – 12 tanks – 1. Demineralization & Sequester.
2. Antifoam
3. Soaping agent
4. Detergent.
5. Deaerating agent.
6. Sequester.
7. Stabilizer.
8. Anti-creasing
9. Sequester 2.
10. Stabilizer 2
11. Detergent 2
12. Caustic Soda
An Example of Chemical dosing storage tanks set-up in the production floor

112
Finishing Machineries
RADIO FREQUENCY DRYER:
No. of m/c : 3
Manufacturer : STRAYFIELD, England. (2) 2007
STALAM, Italy. (1)
Radio Frequency Dryer allows the drying of natural and man-made fibers in staple, hank, cone,
package and top form normally immediately after hydro-extraction. The result is good uniformity
and better final handling.
Advantages
 Uniform drying at low temperature
 Selective heating that only the humid parts are heated
 Energy saving (1.2 kg water per kW/hr high frequency power)
 Power consumption directly proportional to humidity contents
 Improved fiber quality and softness
 Residual humidity controlled within 1%
 Constant and repeatable drying level
 Space saving and possibilities of automation
 Time saving
 Instant controls and adjustments
A 40W STRAYFIELD RF dryer

113
Strayfield:
a) Maximum capacity: 3600 kg
b) Supply voltage: 380-420 v. 230 KVA
c) Conveyor belt speed: Cotton – 8-12 m/hr Polyester – 13-16 m/hr
d) Two drying chambers
e) RF power: 100 KW
Stalam:
a) Capacity: 4000 kg
b) Installed power: 250 KVA
c) Conveyor belt speed: 8-9 m/hr
d) Two chambers
e) RF power: 150 KW
HYDRO EXTRACTOR
 No. of m/c : 2
 Manufacturer : DETTIN, Italy. 2007
 Capacity : 108 kg
 Rotation Speed:1470 rpm
 Power : 16 KW
 Package holder:96
 Centrifugal chamber: 2
 Duration of Rotating: 8 min

114
Production Sequences & Operation

115
LABORATORY:
Lab is the heart of the textile industry Higher precision lab can aid easily to achieve the goal of the
organization Before bulk production a sample for the approval from industry is sent to the buyer as
per the requirement of the buyer the shade is prepared in a lab considering the economic aspects.
LABORATORY STANDARD DYEING CURVE FOR COTTON:
80▫
C × 10'
60▫
C × 30'
35▫
C × 10'
1) Auxiliaries
2) Dyes
3) Glauber salt
4) Fabric
1 2 3 4 5
5) Soda ash
Salt Alkali & acid requirement:
Dyestuff % <0.5 0.6 -1.0 1.10-2.0 2.10-3.0 3.10-5.0
Glauber
g /L 20 30 40 50 60
Salt
Soda ash g /L 10 10 15 15 20
Acetic
ml 0.5 0.5 0.5 0.5 0.5
Acid
Amount of Caustic:
Dye Shade % Amount(g/L)
Black 6-7 1
Red >5 0.5-1
LABORATORY STANDARD DYEING OF POLYESTER:
135c X 45’
80cx20’
Cold
Wash
Reduction
Clearing

116
Chemicals
UNIVADINE DIF
CIVATEX -AB- 45
Acetic Acid
pH
Time
Temp.
For Reduction Cleaning:
Chemicals
Detergent
Caustic Soda
Hydrose
Acetic Acid
Limit (g/L)
1
1
1
4-4.5
45 min
130▫C
% Medium Shade Dark Shade
g/L 0.5 0.5
g/L 1 2
g/L 2 4
g/L 0.5 0.5
Lab line:
1. Standard sample:
The buyer to the merchandising section of the industry gives the order by colored swatch or by using
PANTONE BOOK CODE. This is called Standard sample. The sample is measured by the CCM to get
the recipe. The most recipes are chosen by metamerism value under three light source, price &
dyestuff availability. Naturally up to 0.5 is accepted Sometimes some buyer supply the reflectance
curve & reflectance % of different wavelength from 400 -700 nm. Data are input to the computer;
most recipes are chosen by same way.
2. Lab trial:
Getting the recipe, the lab officer produce lab trial & match with standard according to
buyer requirement Lab trial is made by the AHIBA dyeing machine.
PROGRAM NO TEMPERATURE (▫C) TIME (min)
01 100 60
02 90 60
03 80 60
04 60 60
05 130 45
06 98 45

117
Bulk Dyeing Process
Process for White Shade:
Hot Wash 80c x 10’
Drain
Demineralizing agent + Acetic Acid > 50c x 20’
Detergent + Sequester + Deaerating + Peroxide Stabilizer + Caustic > dosing 5’ > (50c X5’)
Liquor return to preparation tank
Brightener BHV
Runtime 5 min at 60c
Peroxide dosing 5 min
Runtime 20 min at 120c
Cooling
Sample Check
Process follow-up:
YARN DYEING RECIPE #1
SHADE : 55-006 (Pink)
YARN TYPE : 40/1, COMB
M:L : 1:7
(g/L) (%)
P Demineralization
R
Sirrix 2UD (Sequestering) 1.0 -
Acetic Acid 0.3 -
E
T Scouring & Bleaching
Kappawet BOS (Detergent) 1.5 -

118
R
E
A
TM
E
N
T
DY
E
I
NG
A
F
T
E
R
T
R
E
A
TM
E
N
T
Parmagen NF (Deaerating) 0.2 -
Kappazon H53 (Stabilizer) 1.0 -
Caustic Soda 2.0 -
H2O2 (50%) 3.0 -
Hot wash with Peroxide Killer
Chromalese PQ 0.3 -
Neutralization after Bleaching
Acetic Acid 0.5 -
Dyeing
Cibacell DBC (Levelling) 1.5 -
Imcozin Red E3BF - 0.52716
Imcozin Orange E2R - 0.05344
Imcozin Blue ENR - 0.0057
Glauber Salt 25 -
Soda 15 -
Neutralization after dyeing
Acetic Acid 1.0 -
Soaping
Albatex AD (Washing off) 1.0 -
Finishing
Permafix RD (Fixing) - 0.5
Tubingal 1112 (Softener) - 1.5
Oiling CT-200 (Softener) - 1.5
YARN DYEING RECIPE #2
SHADE : Grass Green
YARN TYPE : 30/1, COTTON
M:L : 1:7
(g/L) (%)
P Demineralization
R
Sirrix 2UD (Sequestering) 1.0 -
Acetic Acid 0.3 -
E
Scouring & Bleaching

119
T Kappawet BOS (Detergent) 1.5 -
R
E Kappazon H53 (Stabilizer) 1.0 -
A Caustic Soda 2.0 -
H2O2 (50%) 3.0 -
T
M Hot wash with Peroxide Killer
E
Chromalese PQ 0.3 -
N Neutralization after Bleaching
T
Acetic Acid 0.5 -
D Dyeing
Y
Cibacell DBC (Levelling) 2.0 -
E
I
Synozol Yellow KHL - 0.368
Synozol Red KHL - 0.0215
N
Synozol Blue KRL - 0.2419
G
Glauber Salt 25 -
Soda 15 -
A Neutralization after dyeing
F
Acetic Acid 1.0 -T
E
R Soaping
T
Albatex AD (Washing off) 0.3 -R
E
A Finishing
T Permafix RD (Fixing) - 0.5
M
E
N Tubingal 1112 (Softener) - 1.5
T Oiling CT-200 (Softener) - 1.5

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